Robotic Machine-Tending Software Leverages Simulations

A point of emphasis for industrial robotics going into the future is the trend of suppliers offering simpler software solutions, driven by strong feedback from customers that software complexity is a key difficulty.

An example of how industry is responding is new industrial robot machine-tending software that allows simulation, validation, and software optimization to be completed in a 3D virtual environment, and then transferred to the robot controller. The use of simulations is not new but is an example of how an extra layer of visualization software can enhance the user experience.

Cycle times and potential collision risks can be simulated virtually before costly mistakes are made on the factory floor. (Source: ABB Robotics)

ABB Robotics believes this overhauled system for robotic machine tending software can be used in applications ranging from die-casting to injection molding and machining. "Everything from cycle times to post processing capabilities to potential risks for collisions can be simulated virtually before costly mistakes are made on the factory floor."

Terry Crunk, machine tending specialist for ABB Robotics, said in the press release:

With this new system of software we’ve hit many of the main considerations. It’s easy, fast, and flexible to program machine tending cells, and our control software is usable by even less skilled workers. These are things our customers are always requesting.

Users gain access to these features using the RobotStudio Machine Tending PowerPac. From a conceptual point of view, programming is achieved in a sequence of steps, defining parts produced in the cell, grippers used, and configuration of different stations within a cell, including movements between stations and production cycles.

New PC-based RobotStudio Machine Tending PowerPac and controller-based RobotWare Machine Tending software allows for simulation, validation, and optimization to be completed in the 3D virtual world and then transferred directly to the real-world.
(Source: ABB Robotics)

With a library of common grippers and station types plus built-in support for most machines and peripheral equipment, the process of getting a cell up and running in the virtual world is simplified. In addition, safety is simplified with the capability to define safe home position movements in a virtual environment.

The idea is that using the interactive user interface for program creation and graphical representations for settings and features simplifies the process. The system creates a limited need to use the company’s RAPID code only for advanced features and functions. Logic built into templates, and reuse of experience (including the gripper and part libraries for reuse), and modifying and reusing available templates and libraries (along with user-defined stations, grippers, and parts) speeds the development process.

The Machine Tending PowerPac is a good example of how industrial control software in general, and robotic software in particular, is advancing its agenda of better ease of use. In the case of the ABB software, the ability to provide simulation, validation, and optimization advances the solution to another level. This enables the end user to verify the robot program and to simulate complete machine tending cycles prior to deployment. The user can easily validate the robot’s reach, potential collisions, and optimize movements and robot positions to shorten cycle times.

I think we can expect to see this trend continue, especially as supplies continue to incorporate simulation tools to visualize the process on both development screens and operator interfaces.

For those attending the Design and Manufacturing Midwest Show in Chicago, September 10-12, you may want to check out the "Advanced Robotics Applications in Manufacturing" seminar. This session will address how robotic automation is changing the face of North American manufacturing and offer insights into advances on robot accuracy and how to measure it.

@Charles, I agree, many companies would want to have their own professional solve the problem out and in timely fashion. Without relying on the outside specialized help, because it will lead eventually to high maintenance costs and more loss of critical manufacturing time. The latest softwares are empowering the non technical and non specialized personnel to reconfigure and program the robotic machines by themselves.

Chuck, The key is that the extra level of software enables non-programmers to more easily "re-configure" the underlying software operation. The ability to visualize the changes just makes the entire process easier to use.

The fact that "control software is usable by even less skilled workers" seems to be a key here. Most manufacturers are do-it-yourselfers; they'd rather do software updates and changes on their own, rather than calling for, or hiring, specialized help.

taimoortariq, You are exactly right. Robotic programming languages have always been known as complicated and laborious to update. This kind of interface makes it possible to change the underlying control code without needing a software jock to do it.

Mydesign, The idea is that the software both allows the user to visualize the change in the process using the animation (along with validating the new process), and then also automatically update the control software.

@Naperlou, In manufacturing, cost and expenses are definetly a major area to consider but so is the time which is directly linked to cost as well. To program and test might utilize a fairly decent amount of time, and then the risk of a "bad code" is also there, which can be detrimental to the robot or the workstation as well. I believe that if there is a detailed simulation software out there, it is always good to trust the simulation, do some rigourous testing at the software side, and then integerate it with the controller.

"The idea is that using the interactive user interface for program creation and graphical representations for settings and features simplifies the process"

To be able to program robots by using graphical methods and inbuilt functions is a great feature to have, since it is adding simplicity to the complicated process and flexibility to test it. I remember when we were working with Industrial robots we had right the G codes line by line to bring about manufacturing of a workpiece and handling it. But having a user friendly interface will save a great hastle.

Simulation is also made easier becuase all aspects of the process tend to use detailed models. These can then be eaisly integrated to create a complete model of the situation. When there are aspects that are not already modeled, then the cost of modeling them might be a detriment to this approach. In other words it might be cheaper to program and test.

"new industrial robot machine-tending software that allows simulation, validation, and software optimization to be completed in a 3D virtual environment, and then transferred to the robot controller."

Presher, simulation is a part of visualization where the developer will be able to know how their system is responding at various commands in real time mode. So any addition to the simulation process can increase clarity and transparency in performance monitoring.

If a major catastrophe strikes your area, will you be prepared? Do you know how to modify the tech you've already got or MacGyver what you need to fit your own situation? A free, five-day Continuing Education Center course starting April 6 will show you how.

Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.